CN110291608B

CN110291608B - Power relay assembly

Info

Publication number: CN110291608B
Application number: CN201880011379.2A
Authority: CN
Inventors: 元民豪; 黄胜载
Original assignee: Amogreentech Co Ltd
Current assignee: Amogreentech Co Ltd
Priority date: 2017-03-06
Filing date: 2018-03-06
Publication date: 2021-10-15
Anticipated expiration: 2038-03-06
Also published as: CN110291608A; JP2020511782A; EP3594984A1; EP3594984B1; KR102119594B1; JP6913967B2; US20200055466A1; KR20180102020A; EP3594984A4; US11420572B2; EP3594984C0

Abstract

A power relay assembly is provided. The power relay assembly of an exemplary embodiment of the present invention includes: a support plate, which is provided with at least one electrical element on one surface and comprises a plastic material with heat dissipation and insulation properties; at least one bus bar electrically connected to the electrical component; and an electromagnetic wave shielding part for shielding the electromagnetic wave generated by the electric element.

Description

Power relay assembly

Technical Field

The present invention relates to a power relay assembly, and more particularly, for example, to a power relay assembly that can be used for an electric vehicle.

Background

An electric vehicle is a generic term for a vehicle that runs using electricity. Generally, Electric vehicles are classified into Electric Vehicles (EV) that operate only by electricity, Hybrid Electric Vehicles (HEV) that use electricity and fossil fuel, and the like.

In an electric vehicle, a power relay Assembly (PowerRelay Assembly) is disposed between a high-voltage battery and a motor. Such a power relay assembly functions as a power source that selectively supplies the high-voltage battery.

That is, the power relay assembly includes a main relay (main relay), a Pre-charge relay (Pre-charge), a Pre-charge resistor (Pre-charge resistor), and the like, which are electrically connected to each other via a bus bar.

The main relay supplies or cuts off power between the high-voltage battery and the motor, and the pre-charge relay and the pre-charge resistor prevent damage of the device caused by initial current.

Also, the bus bars, which are conductors having low impedance and high current capacity, may individually connect 2 or more circuits or connect a plurality of equivalent points within one system.

In general, a power relay unit is mounted on a trunk or a cabin (cabin room) for connection to a high-voltage battery provided on the trunk. Therefore, it is necessary to prevent not only the performance degradation and damage due to heat but also the abnormal operation and damage due to electromagnetic waves by securing the heat radiation performance and electromagnetic wave shielding performance of the main relay or the precharge relay.

Disclosure of Invention

Solves the technical problem

The present invention has been made in view of the above problems, and an object of the present invention is to provide a power relay assembly capable of ensuring both heat dissipation performance and an electromagnetic wave shielding function.

Technical scheme

In order to solve the above problem, the present invention provides a power relay assembly including: a support plate, which is provided with at least one electrical element on one surface and comprises a plastic material with heat dissipation and insulation properties; at least one bus bar electrically connected to the electrical component; and an electromagnetic wave shielding part for shielding the electromagnetic wave generated by the electric element.

The electromagnetic wave shielding part may be a plate-shaped metal member embedded in the support plate, and the metal member may be electrically connected to a ground via a cable.

As another example, the electromagnetic wave shielding part may be a shielding coating layer having conductivity. In this case, the barrier coating layer may be formed on an inner surface of the cover for preventing the bus bar from being exposed to the outside.

As yet another example, the support plate may include: a first plate made of a plastic material having insulation and heat dissipation properties; a second plate made of a plastic material having non-insulating and heat dissipating properties and containing a conductive filler, the second plate being laminated on one surface of the first plate; the electromagnetic wave shielding part may be the second plate.

In addition, at least a part of the bus bar may be embedded in the support plate. In this case, the bus bar may be disposed so that at least a part of the portion embedded in the support plate is in contact with the portion of the support plate made of the plastic material having the heat radiation property and the insulation property.

Effects of the invention

According to the present invention, the support plate is provided with heat dissipation properties, and the electromagnetic wave shielding portion shields electromagnetic waves while preventing performance degradation and component damage due to heat in advance, thereby preventing electronic components from malfunctioning and being damaged due to electromagnetic waves.

Drawings

Figure 1 is a diagrammatic view of a power relay assembly showing one embodiment of the present invention,

fig. 2 is a view showing a state in which the electric element is removed in fig. 1, showing a positional relationship of bus bars,

FIG. 3 is a view showing a state where the first plate, the second plate and the third plate are separated in FIG. 2,

figure 4 is a cross-sectional view taken along line B-B of figure 2,

fig. 5 to 7 are sectional views showing various forms of the support plate as viewed in the same direction as fig. 4, as views showing a state where the electromagnetic wave shielding part is provided as a metal member in the power relay assembly according to the embodiment of the present invention,

fig. 8 is a view conceptually showing a state where the metal member of fig. 4 is connected to the ground,

fig. 9 and 10 are cross-sectional views, viewed in the same direction as fig. 4, showing another form of an electromagnetic wave shielding part in a power relay assembly according to an embodiment of the present invention,

fig. 11 is a sectional view showing a state where an electromagnetic wave shielding part is formed on an inner surface of a cover with a shield coating layer as a sectional view of the cover applicable in the power relay assembly of one embodiment of the present invention viewed in the same direction as the direction of a-a of fig. 1,

fig. 12 is a sectional view showing a bus bar applicable in the power relay assembly according to one embodiment of the present invention, which is a view showing a case where a coating layer is formed on a surface,

fig. 13 is a schematic view showing a state in which a power relay assembly according to an embodiment of the present invention is attached to a housing of an electric vehicle, and,

fig. 14 is a schematic view showing a state in which a power relay assembly according to an embodiment of the present invention is attached to an electric vehicle case and sealed by a cover.

Detailed Description

Embodiments of the present invention will be described in detail below with reference to the accompanying drawings so that those skilled in the art can easily implement the present invention. The present invention may be embodied in many different forms and is not limited to the embodiments described herein. In order to clearly explain the present invention in the drawings, portions that are not related to the description are omitted, and the same reference numerals are given to the same or similar constituent elements throughout the specification.

The power relay assembly 100 according to an embodiment of the present invention is used to cut off or connect a high voltage current supplied from a battery and supply power to a driving control part controlling a driving voltage, and as shown in fig. 1, may include a support plate 110, at least one

electric component

10, 20, 30, a bus bar 120, a cover 130, and an electromagnetic wave shielding part.

The support plate 110 may have a plate shape having a predetermined area, and may fix the at least one

electric component

10, 20, 30 and the bus bar 120 electrically connecting the same.

In this case, at least a portion of the support plate 110 may have both heat dissipation and insulation properties.

That is, the portion of the support plate 110 having heat dissipation properties, which can release heat generated when the electric components are operated, can perform a role of supporting the

electric components

10, 20, 30 and the bus bars 120. In addition, the insulating portion of the support plate 110 prevents an electrical short between the bus bar 120 and the

electrical components

10, 20, and 30.

The support plate 110 may be formed of a plastic material, and according to an embodiment of the present invention, at least a portion of the support plate 110 may be formed of a plastic material having heat dissipation and insulation properties, and a portion of the bus bar 120 may be fixed to be in contact with the portion having heat dissipation and insulation properties.

In this case, the support plate 110 may be partially formed of a plastic material having heat dissipation and insulation properties, but is not limited thereto, and the support plate 110 may be entirely formed of a plastic material having heat dissipation and insulation properties.

The bus bar 120 may be electrically connected to at least one

electrical component

10, 20, 30 mounted on one surface of the support plate 110.

For this purpose, the bus bar 120 may be formed of a conductor having a low impedance and a high current capacity, and may individually connect 2 or more electrical components, or connect a plurality of equivalent points, thereby performing a function of distributing power to a plurality of points.

Such a bus bar 120 may be provided in a plate-shaped bar having a predetermined length. The bus bar 120 may be bent 1 or more times in a part of the entire length thereof so as to be easily fastened to the

electric components

10, 20, and 30. However, the overall shape of the bus bar 120 is not limited to this, and may be appropriately changed according to the arrangement position of the

electrical components

10, 20, and 30 to be connected to each other.

In addition, the bus bar 120 may be provided in plurality. Thereby, at least a part of the plurality of bus bars 120 may be connected to the positive and negative terminals of the battery, the positive and negative terminals of the inverter, and the like, respectively, and the plurality of

electric elements

10, 20, and 30 may connect or disconnect the high-voltage current supplied from the battery to the driving control unit.

At this time, the bus bar 120 may be fixed in a state where at least a portion thereof contacts the support plate 110, and a portion of the bus bar 120 contacting the support plate 110 may be a portion of the support plate 110 having heat dissipation properties.

Therefore, when the power relay assembly 100 according to the embodiment of the present invention is operated, the heat generated from the

electric components

10, 20, 30 and/or the bus bars 120 may be released to the outside through the bus bars 120 contacting the support plate 110 and through the portion of the support plate 110 having the heat dissipation property. Therefore, the power relay assembly 100 according to an embodiment of the present invention can prevent the performance degradation and the damage of the components due to heat in advance.

In this case, the bus bar 120 may be fixed to one surface of the support plate 110, but at least a part of the entire length of the bus bar 120 may be embedded in the support plate 110. As an example, the bus bar 120 may include a first portion 121, a second portion 122, and a third portion 123.

The first portion 121 may be a portion completely embedded in the supporting plate 110, the third portion 123 may be a portion exposed to the outside of the supporting plate 110, and the second portion 122 may be a portion connecting the first portion 121 and the third portion 123 and fixed by the supporting plate 110.

When the support plate 110 includes a portion made of the plastic material having heat dissipation and insulation properties, the first portion 121 of the bus bar 120 may be embedded in the support plate 110 so as to be in contact with the portion made of the plastic material having heat dissipation and insulation properties. The detailed description thereof will be described later.

On the other hand, the bus bar 120 may be formed of a conductor having low impedance and high current capacity, as described above. As a specific example, the bus bar 120 may be made of a metal material such as copper or aluminum.

In the case where the bus bar 120 is made of an aluminum material, the bus bar 120 may have a heat dissipation coating layer C coated on the surface thereof as shown in fig. 12, and the heat dissipation coating layer C may be the same as the protection coating layer 150 including an insulating heat dissipation filler, which will be described later. That is, the bus bar 120 made of the aluminum material may have a lighter weight than the bus bar 120 made of the copper material. This is because aluminum has a relatively smaller specific gravity than copper in terms of material characteristics. Therefore, the power relay assembly using aluminum as the material of the bus bar 120 may have a lighter weight than the power relay assembly using copper as the material of the bus bar 120.

On the contrary, since aluminum has a relatively smaller thermal conductivity than copper in material characteristics, heat dissipation performance is deteriorated when fabricated to the same size, and in order to embody the same level of heat dissipation performance, there is a disadvantage that the bus bar should be made thicker in thickness.

In the present invention, in order to solve such a problem, when the bus bar 120 is made of an aluminum material, the heat dissipation coating layer C including an insulating heat dissipation filler is formed on the surface of the bus bar 120, and the heat dissipation performance is improved, so that the same level of heat dissipation performance can be embodied while minimizing an increased thickness as compared with the case where the bus bar is made of a copper material.

Therefore, the power relay module using aluminum as the material of the bus bar 120 can be lighter and can save the manufacturing cost, compared to the power relay module using copper as the material of the bus bar 120.

As a non-limiting example, a bus bar made of an aluminum material should be made approximately 1.5 times as thick to exhibit a heat radiation performance at the same level as a bus bar made of a copper material having the same shape. However, when the heat dissipation coating layer C including the insulating heat dissipation filler is formed on the surface of the bus bar, that is, the bus bar made of the aluminum material and having the heat dissipation coating layer C including the insulating heat dissipation filler formed on the surface thereof, the heat dissipation performance can be exhibited at the same level even if the thickness thereof is approximately 1.3 times as large as that of the bus bar made of the copper material.

However, the material of the bus bar 120 is not limited thereto, and any conductor having low impedance and high current capacity may be used without limitation.

The cover 130 prevents the

electric components

10, 20, and 30 and the bus bar 120 protruding from one surface of the support plate 110 from being exposed to the outside, thereby protecting the

electric components

10, 20, and 30 and the bus bar 120 from the external environment.

Such a cover 130 may be directly fastened to the support plate 110, or may be fastened to a bracket, not shown, provided independently on the edge side of the support plate 110. Also, the cover 130 may be in the shape of a box with one side open.

However, the cover 130 is not limited thereto, and the cover 130 may be formed of one member or may be assembled of a plurality of parts to form one box. The cover 130 may cover one support plate 110 as shown in fig. 1 and 13, or may cover a plurality of support plates 110 arranged adjacent to each other by one cover 130 as shown in fig. 14.

The cover 130 may be made of an insulating general plastic material, but at least a part thereof may be made of a plastic material having heat radiation and insulation properties, like the support plate 110.

The electromagnetic wave shielding part can prevent the electronic component from abnormal operation and damage caused by the electromagnetic wave. Therefore, the power relay assembly 100 according to an embodiment of the present invention can prevent the performance degradation and the damage of the components due to heat in advance by the support plate 110 having the heat radiation property, and simultaneously prevent the problems such as the malfunction and the damage of the electronic components due to the electromagnetic wave by the electromagnetic wave shielding part.

Such an electromagnetic wave shielding part may be provided on the support plate 110 or on the cover 130 side.

As a specific example, the electromagnetic wave shielding part may be a plate-shaped metal member 140 buried in the

support plates

110 and 210, as shown in fig. 4 to 7.

In this case, the metal member 140 may be a sheet-like plate or a metal mesh.

Such a metal member 140 may be embedded in a portion of the

support plate

110 or 210 made of a plastic material having insulation and heat dissipation properties so as to prevent an electrical short circuit. As an example, the metal member 140 may be integrated with the portions of the

support plates

110 and 210 made of plastic materials having insulation and heat dissipation properties by insert injection molding.

Therefore, even if the

support plates

110 and 210 shown in fig. 4 to 7 are made of a plastic material, the metal member 140 can exhibit an electromagnetic wave shielding function and improve mechanical strength. Moreover, even if the

support plates

110 and 210 are formed of injection-molded parts, the metal member 140 can improve mechanical strength, and thus can be embodied with a thin thickness.

In the present invention, when the metal member 140 is made of a metal material having a predetermined thermal conductivity, the metal member can be used without limitation. As a non-limiting example, the metal member 140 may be 1 metal selected in the group consisting of aluminum, magnesium, iron, titanium, and copper or an alloy containing at least 1 metal selected.

The metal member 140 may be embedded in the

support plates

110 and 210 so that the front surface thereof is completely surrounded by a portion made of a plastic material having insulation and heat dissipation properties as shown in fig. 4 and 6, or may be disposed on the bottom surfaces of the

support plates

110 and 210 so that the metal member is in contact with the portion made of the plastic material having insulation and heat dissipation properties and is exposed to the outside as shown in fig. 5 and 7.

On the other hand, in the case where the metal member 140 is integrated with the

support plates

110 and 210 by insert molding, the metal member 140 may be surface-treated so as not to be separated from the interface with the portions of the

support plates

110 and 210 made of a plastic material having insulation and heat dissipation properties. Accordingly, the

support plates

110 and 210 can improve the coupling force between the metal member 140 and the portion made of the plastic material having insulation and heat dissipation properties. Alternatively, the metal member 140 may have nano-sized minute grooves formed in a predetermined pattern on at least one surface thereof in order to improve the bonding strength with the portion made of the plastic material having insulation and heat dissipation properties.

On the other hand, in the case where the

support plate

110, 210 includes the metal member 140 functioning as an electromagnetic wave shielding part, the metal member 140 may be disposed to maintain a predetermined interval d from an end of the bus bar 120 at least a part of which contacts the

support plate

110, 210.

As a specific example, the spaced distance d between the metal member 140 and the first portion 121 of the bus bar 120 contacting the

support plates

110, 210 may have a spacing of 1mm or more. This is to satisfy the required voltage resistance while maintaining the insulation properties.

In the present invention, the metal member 140 may be a plate-shaped metal plate having a predetermined area, as described above. However, the metal member 140 is not limited thereto, and may be provided in a rod shape having a predetermined aspect ratio. The metal member 140 may be a mesh type (mesh type) having a closed edge such as a square or a circle, and a plurality of wires or strips spaced at predetermined intervals inside the edge. When the metal member 140 is a mesh type, a plurality of metal wires or strips disposed inside the edge may be disposed to form a parallel structure, a lattice structure, a honeycomb structure, and various combinations thereof.

On the other hand, when the

support plates

110 and 210 include the metal member 140 functioning as an electromagnetic wave shielding part, the metal member 140 may be connected to a ground terminal (earth terminal) via a cable.

As an example, as shown in fig. 8, the metal member 140 embedded in the front of the support plate 110 may be connected to a ground terminal (earth terminal) via a cable. Therefore, the electromagnetic wave absorbed by the metal member 140 is moved to the ground side through the cable and the ground terminal, and the electromagnetic wave shielding performance can be further improved. In the drawings and the description, the metal member 140 is connected to the ground terminal via a cable in order to improve the electromagnetic wave shielding performance, but the present invention is not limited thereto, and any form may be used as long as the form can discharge the electromagnetic wave absorbed by the metal member 140 to the outside. In the drawings, the form shown in fig. 4 is illustrated as being connected to the ground terminal via a cable, but the present invention is not limited thereto, and the same applies to the

support plates

110 and 210 shown in fig. 5 to 7.

As another example, the electromagnetic wave shielding part may be embodied in the forms shown in fig. 9 and 10. That is, in the present embodiment, a portion of the support plate 310 contains a conductive component, so that the electromagnetic wave shielding part can embody an electromagnetic wave shielding function.

To this end, the support plate 310 may include a first plate 312 and a second plate 314 having plate shapes stacked on each other. In this case, the first plate 312 may be made of a plastic material having heat dissipation and insulation properties, and the second plate 314 may be made of a plastic material having heat dissipation and non-insulation properties. Also, the second plate 314 may include a conductive filler so that an electromagnetic wave shielding function may be embodied.

At this time, the second plate 314 may simultaneously perform the role of the electromagnetic wave shielding part while constituting a part of the support plate 310.

Specifically, the first plate 312 may be in a form in which an insulating heat dissipation filler is dispersed in a polymer matrix so as to have heat dissipation and insulation properties, and the second plate 314 may be in a form in which a heat dissipation filler and a conductive filler are dispersed in a polymer matrix.

In this case, the first plate 312 and the second plate 314 may be injection-molded parts formed by injection molding, and the support plate 310 may be formed in a manner that the first plate 312 and the second plate 314 are integrated by double injection molding.

In this case, the bus bar 120 may be disposed to contact the first plate 312 having heat dissipation and insulation properties among the support plates 310.

That is, the bus bar 120 may be partially embedded in the first plate 312 as shown in fig. 9, or may be fixed in a state where one surface thereof contacts one surface of the first plate 312 as shown in fig. 10.

Therefore, even if the support plate 310 in this embodiment is fixed in a state in which a part of the bus bar 120 is in contact with the first plate 312 having insulation, the support plate is in contact with and fixed to the first plate 312, thereby preventing an electrical short circuit, and the electromagnetic wave can be smoothly absorbed and cut by the second plate 314.

However, the polymer matrix constituting the first plate 312 and the second plate 314 may be used without limitation when it is a polymer compound that can be injection molded without impairing the dispersibility of the heat-dissipating filler. In addition, any material can be used without limitation as long as it can exhibit good adhesion without limiting adhesion between different materials.

As a specific example, the polymer matrix may be a known thermoplastic polymer compound, and the thermoplastic polymer compound may be one compound selected from the group consisting of polyamide, polyester, polyketone, liquid crystal polymer, polyolefin, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyphenylene oxide (PPO), polyether sulfone (PES), polyether imide (PEI), and polyimide, or a mixture or copolymer of two or more thereof.

The insulating heat-dissipating filler included in the first plate 312 may be used without limitation as long as it has both insulating property and heat-dissipating property. As a specific example, the insulating heat dissipation filler may include 1 or more selected from the group consisting of magnesium oxide, titanium dioxide, aluminum nitride, silicon nitride, boron nitride, aluminum oxide, silicon dioxide, zinc oxide, barium titanate, strontium titanate, beryllium oxide, silicon carbide, and manganese oxide. In this case, the insulating heat dissipating filler may be porous or non-porous, or may be a core-shell type filler in which a known conductive heat dissipating filler such as carbon, metal, or the like is used as a core and an insulating component surrounds the core. In the case of the insulating heat-dissipating filler, the surface may be modified with a functional group such as a silane group, an amino group, a hydroxyl group, or a carboxyl group so as to improve wettability and the interfacial bonding force with the polymer matrix.

The conductive filler contained in the second plate 314 may be any known conductive filler, and may be used without limitation. As an example, the conductive filler may include one or more metals selected from the group consisting of aluminum, nickel, copper, silver, gold, chromium, platinum, titanium alloy, and stainless steel, and one or more conductive polymer compounds. In this case, the conductive polymer compound may include a compound selected from the group consisting of polythiophene (polythiophene), poly (3,4-ethylenedioxythiophene), polyaniline (polyaniline), polyacetylene (polyacetylene), polydiacetylene (polydiacetylene), polythienylene (polythienylene), polyfluorene (polyfluorene), and poly (3,4-ethylenedioxythiophene) (PEDOT): sodium polystyrene sulfonate (PSS).

In the present embodiment, although the first plate 312 and the second plate 314 are provided in the same shape in the drawings, the present invention is not limited to this, and the first plate 312 and the second plate 314 may be laminated to each other such that the edge side of the second plate 314 surrounds the edge of the first plate 312, or the first plate 312 and the second plate 314 may be laminated to each other such that the edge side of the first plate 312 surrounds the edge of the second plate 314.

As another example, the electromagnetic wave shielding part may be provided on one surface of the cover 130, as shown in fig. 11. That is, in the present embodiment, the electromagnetic wave shielding part may be a shielding coating layer 240 having conductivity and formed in a predetermined thickness on the inner surface of the cover 130 so as to be able to shield the electromagnetic wave, and the shielding coating layer 240 may be a polymer resin layer containing a conductive filler or a deposition layer deposited with a metal substance.

The polymer resin layer containing the conductive filler may be a form in which the conductive filler is dispersed in a known thermosetting polymer compound or a known thermo-reversible polymer compound. The conductive filler may include one or more metals selected from the group consisting of aluminum, nickel, copper, silver, gold, chromium, platinum, titanium alloy, and stainless steel, and one or more conductive polymer compounds. In this case, the conductive polymer compound may include a compound selected from the group consisting of polythiophene (polythiophene), poly (3,4-ethylenedioxythiophene), polyaniline (polyaniline), polyacetylene (polyacetylene), polydiacetylene (polydiacetylene), polythienylene (polythienylene), polyfluorene (polyfluorene), and poly (3,4-ethylenedioxythiophene) (PEDOT): sodium polystyrene sulfonate (PSS).

Further, the deposition layer may be used without limitation as long as it is a metal substance that can be deposited like aluminum, nickel, copper, silver, gold, chromium, platinum, titanium alloy, stainless steel, and the like.

In the present embodiment, the barrier coating layer 240 may be formed only on the inner surface of the cap 130, but is not limited thereto, and may be coated on the outer surface of the cap 130, or may be coated on both the inner surface and the outer surface of the cap 130. The barrier coating layer 240 may be formed partially on a partial area of the cap 130, or may be formed on the entire area of the cap 130.

The barrier coating layer 240 may be a thin metal film layer formed by adhering a thin metal plate with an adhesive layer as a medium, in addition to the coating layer or the deposition layer.

On the other hand, in the power relay assembly 100 according to one embodiment of the present invention, in the case where the electromagnetic wave shielding part is embodied in the plate-shaped metal member 140, the

support plates

110, 210 may be embodied in various manners.

As an example, the support plate 110 may include a plate-shaped first plate 111, a second plate 112, and a third plate 113, as shown in fig. 1 to 5. In this case, the first plate 111, the second plate 112, and the third plate 113 may be sequentially stacked, and at least the first plate 111 of the first plate 111, the second plate 112, and the third plate 113 may be formed of a plastic material having heat dissipation properties and insulation properties.

In this case, as shown in fig. 2 and 3, the second plate 112 and the third plate 113 may include a first portion 121 embedded in the support plate 110 in the bus bar 120 and

arrangement holes

114a and 114b having shapes corresponding to those of the second portion 122, and the arrangement holes 114a and 114b may be formed to penetrate the second plate 112 and the third plate 113, respectively. In this case, the shape of the arrangement holes 114a and 114b may be appropriately changed according to the shape of the first portion 121 and the second portion 122 of the bus bar 120 embedded in the support plate 110.

Therefore, heat generated during operation of the

electric components

10, 20, and 30 and the bus bar 120 can be transmitted to the outside after being transmitted to the first plate 111 side having heat radiation properties. The bus bar 120 may be fixed by the second plate 112 and the third plate 113 in a state where the second portion 122 is embedded in the support plate 110. Thus, the power relay assembly 100 of the present embodiment does not require an additional fixing member for fixing the bus bar 120 to the support plate 110, so that efficient use of space can be achieved and assembly work can be simplified.

Among them, the first plate 111, the second plate 112, and the third plate 113, which are sequentially stacked, may be attached to each other through an adhesive member (not shown in the drawings). At this time, the adhesive member may use a general adhesive member, but preferably, a heat dissipating adhesive member containing a thermally conductive filler may be used. The first plate 111, the second plate 112, and the third plate 113 may be attached to each other by using a known heat transfer material (not shown) such as a thermal interface material (Tim) as an intermediate. The first plate 111, the second plate 112, and the third plate 113 may be stacked in this order and fixed with a fastening member (not shown) such as a bolt member as a medium.

On the other hand, in the case where the support plate 110 is formed by separating the first plate 111, the second plate 112, and the third plate 113, the first plate 111 may be made of a plastic material having heat dissipation properties and insulation properties, and the second plate 112 and the third plate 113 may be made of a general plastic material having insulation properties.

At this time, heat transferred to the first plate 111 side having heat radiation properties through the bus bars 120 can be blocked from transferring in the vertical direction by the second plate 112 and/or the third plate 113 stacked on the first plate 111. Therefore, the heat transferred to the first plate 111 can be blocked from being transferred to the

electric elements

10, 20, and 30 through the second plate 112 and/or the third plate 113.

Therefore, heat generated in the bus bar 120 can be concentrated on the first plate 111 side due to the heat release path, so that the heat dissipation performance can be improved.

Further, in the power relay assembly 100 according to the present invention, as shown in fig. 13 and 14, when the external air contacts the lower portion side of the case 1 by the natural convection or the forced convection in a state where one or more cases are disposed inside the case 1 having a box shape, the heat generated from the

electric elements

10, 20, 30 and/or the bus bar 120 can be concentrated on the first plate 111 directly contacting the case 1, and the power relay assembly 100 can more efficiently dissipate the heat.

On the other hand, when the support plate 110 is formed by separating the first plate 111, the second plate 112, and the third plate 113, the second plate 112 and the third plate 113 may be formed of a plastic material having heat dissipation and insulation properties, as in the case of the first plate 111. That is, the support plate 110 may be entirely made of a plastic material having heat dissipation properties. In this case, as compared with the case where only the first plate 111 is made of a plastic material having heat dissipation and insulation properties, the heat capacity of the entire support plate 110 is increased, and heat dissipation properties are improved.

Alternatively, as shown in fig. 6, the support plate 210 may be an injection-molded part made of a resin composition having heat dissipation and insulation properties.

That is, the support plate 210 may be entirely made of a plastic material having heat dissipation and insulation properties, and the bus bar 120 may be integrally formed with the support plate 210. In the process of molding the support plate 210 by insert molding using the resin-forming composition, the bus bar 120 may be integrated with the support plate 210 in a form in which at least a part thereof is embedded in the resin-forming composition, and the first portion 121 and the second portion 122 may be embedded in the support plate 210.

Therefore, as described above, the support plate 210 of the present embodiment is formed by separating the first plate 111, the second plate 112, and the third plate 113, and thus, as with the support plate 110 in which the first plate 111, the second plate 112, and the third plate 113 are each made of a plastic material having heat dissipation properties and insulation properties, it is possible to increase the overall heat capacity and further improve the heat dissipation properties, and it is possible to improve the work productivity because complicated assembly processes are omitted.

On the other hand, the plastic having heat dissipation and insulation properties used to form the

support plates

110 and 210 may be in a form in which an insulating heat dissipation filler is dispersed in a polymer matrix.

As an example, the polymer matrix can be used without limitation when it is a high molecular compound that does not impair dispersibility of the heat dissipation filler and can be injection molded. As a specific example, the polymer matrix may be a known thermoplastic polymer compound, and the thermoplastic polymer compound may be 1 compound selected from the group consisting of polyamide, polyester, polyketone, liquid crystal polymer, polyolefin, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyphenylene oxide (PPO), polyether sulfone (PES), polyether imide (PEI), and polyimide, or a mixture or copolymer of 2 or more thereof.

The insulating heat-dissipating filler can be used without limitation as long as it has both insulating and heat-dissipating properties. As a specific example, the insulating heat dissipation filler may include 1 or more selected from the group consisting of magnesium oxide, titanium dioxide, aluminum nitride, silicon nitride, boron nitride, aluminum oxide, silicon dioxide, zinc oxide, barium titanate, strontium titanate, beryllium oxide, silicon carbide, and manganese oxide.

The insulating heat dissipating filler may be porous or non-porous, or may be a core-shell type filler in which a known conductive heat dissipating filler such as carbon, metal, or the like is used as a core and an insulating component surrounds the core.

The insulating heat-dissipating filler may be modified at the surface with functional groups such as silane groups, amino groups, amine groups, hydroxyl groups, and carboxyl groups, so that the wettability and the interfacial bonding strength with the polymer matrix can be improved.

However, the plastic having both insulation and heat dissipation properties that can be used in the present invention is not limited thereto, and any plastic having both insulation and heat dissipation properties can be used without limitation.

On the other hand, the bus bar 120 may be at least partially embedded in the

support plates

110 and 210 as described above.

Specifically, as shown in fig. 4 to 8, the bus bar 120 may include a first portion 121 embedded in the

support plate

110, 210, and an

extension portion

122, 123 extended from an end of the first portion 121.

In addition, the

extension portions

122 and 123 may include a second portion 122 extending from an end of the first portion 121 in a thickness direction of the

support plate

110 and 210 and a third portion 123 extending from an end of the second portion 122 and protruding to an outer side of the

support plate

110 and 210 in an entire length, and the second portion 122 may be embedded in the

support plate

110 and 210 together with the first portion 121.

The first portion 121 and the second portion 122 embedded in the

support plates

110 and 210 may be disposed in the

disposition holes

114a and 114b formed through the second plate 112 and the third plate 113 when the support plate 110 is embodied in a form of a stack of the first plate 111, the second plate 112, and the third plate 113.

Therefore, the first portion 121 embedded in the support plate 110 may have an upper surface covered with the third plate 113 in a state where a bottom surface thereof contacts the first plate 111, and may be fixed by the second plate 112 and the third plate 113 when the first plate 111, the second plate 112, and the third plate 113 are fixedly coupled. Therefore, the bus bar 120 may be fixed to the support plate 110 even without using an additional fixing member.

In addition, at least the first portion 121 may be disposed to be in direct contact with the first plate 111 made of a plastic material having heat dissipation and insulation properties, embedded in the first portion 121 and the second portion 122 of the support plate 110.

Alternatively, as described above, in the case where the bus bar 120 is entirely made of a plastic material having heat dissipation properties and insulation properties, the bus bar 120 may be embedded in the support plate 210 by performing insert molding in a state where at least a part of the bus bar 120 is embedded in the resin composition in the insert molding process using the resin composition.

In the drawings, one second portion 122 and one third portion 123 extending from the first portion 121 are illustrated, but the present invention is not limited thereto, and a plurality of second portions 122 and a plurality of third portions 123 may be provided.

As shown in fig. 10, the bus bar 120 may be fixed to one surface of the support plate 210, and the bus bar 120 may be fixed to the exposed surface of the support plate 110 shown in fig. 4 to 8 in the same manner as in fig. 10.

In the case where a part of the bus bar 120 is embedded in the

support plate

110 or 210, the first part 121 and the second part 122 of the bus bar 120 embedded in the

support plate

110 or 210 may be externally provided with a known heat transfer material (not shown). Such a heat transfer material can smoothly transfer heat existing in the bus bar 120 to the side of the

support plates

110, 210 having heat dissipation properties.

On the other hand, the power relay assembly 100 of one embodiment of the present invention may further include a protective coating layer 150.

The protective coating layer 150 may be coated to entirely cover the outer surfaces of the

support plates

110 and 210 and the bus bar 120, as shown in fig. 4. The protective coating layer 150 may cover the outer surfaces of the

electrical components

10, 20, and 30 mounted on one surface of the

support plate

110 and 210. However, the position of coating the protective coating layer 150 is not limited thereto, and the protective coating layer may be coated only on the outer surfaces of the

support plates

110 and 210 or only on the outer surfaces of the bus bars 120.

Such a protective coating layer 150 can prevent scratches and the like caused by physical stimuli applied to the surfaces of the

support plates

110 and 210 and the bus bar 120, and can further improve the insulation of the surfaces.

In addition, the protective coating layer 150 may prevent the insulating heat dissipation filler located on the surface from being detached even when the

support plates

110 and 210 are made of plastic in which the insulating heat dissipation filler is dispersed.

As an example, the protective coating layer 150 may be embodied by a known thermosetting polymer compound or thermoplastic polymer compound. The thermosetting polymer compound may be 1 compound selected from the group consisting of epoxy, urethane, ester and polyimide resins, or a mixture or copolymer of 2 or more compounds. The thermoplastic polymer compound may be 1 compound selected from the group consisting of polyamide, polyester, polyketone, liquid crystal polymer, polyolefin, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), polyphenylene oxide (PPO), polyether sulfone (PES), polyether imide (PEI), and polyimide, or a mixture or copolymer of 2 or more compounds, but is not limited thereto.

On the other hand, the protective coating layer 150 is applied to the outer faces of the

support plates

110, 210, thereby preventing the heat transferred to the support plate 110 side from being released to the outside. In order to solve such a problem, the protective coating layer 150 applied in the present invention may further include an insulating heat dissipation filler so that heat radiation characteristics to the outside can be improved. The insulating heat dissipating filler can be used without limitation as long as it is a known insulating heat dissipating filler.

As an example, the protective coating layer 150 may include an insulating heat-dissipating filler dispersed in a polymer matrix, like the

support plates

110 and 210, so as to have both heat dissipation and insulation.

In this case, the insulating heat-dissipating filler contained in the protective coating layer 150 may be the same type as the insulating heat-dissipating filler contained in the

support plates

110 and 210, or may be different.

The plurality of

electric components

10, 20, and 30 may be attached to one surface of the

support plate

110, 210, and 310, and may be electrically connected to each other via the bus bar 120. Thereby, the

electric elements

10, 20, 30 can perform a role of cutting off or connecting the high-voltage current supplied from the battery to the drive control section side.

Such

electrical components

10, 20, 30 may be a main relay, a pre-charge resistor, a battery current sensor, a main fuse, etc., and may be electrically connected to each other via the bus bar 120 or a cable (not shown in the drawing). In addition, the plurality of bus bars 120 may also be electrically connected by a circuit pattern (not shown in the drawing) formed at the

support plate

110, 210, 310.

Thereby, the

electric elements

10, 20, and 30 cut off or connect the high-voltage current supplied from the battery and supply electric power to a drive control unit (not shown) that controls the drive voltage, so that a control signal for driving the motor can be generated in the drive control unit. In this case, the drive control unit may generate a control signal for driving the motor, and may control the inverter and the converter by the control signal, thereby controlling the driving of the motor.

As an example, when the vehicle is running, the main relay is in a connected state and the pre-charge relay is disconnected, so that the power of the battery can be connected to the inverter through the main circuit.

In addition, when the vehicle is turned off, the main relay is in a cut-off state, and the connection of the battery and the inverter is cut off, so that it is possible to prevent the battery voltage from being transmitted to the motor through the inverter. At this time, if the main relay is in the off state, the capacitor connected to the inverter may be discharged.

Then, when the vehicle is restarted, the precharge relay is connected, and the voltage of the battery is connected to the inverter in a state where the voltage is decreased by the precharge resistor, so that the charging of the capacitor can be started. Then, after the capacitor is sufficiently charged, the precharge relay is turned off while the main relay is connected, so that the voltage of the battery can be connected to the inverter.

The operation of such electrical components is well known and therefore, a detailed description thereof is omitted.

While one embodiment of the present invention has been described above, the idea of the present invention is not limited to the embodiment presented in the present description, and a person skilled in the art who understands the idea of the present invention can easily propose other embodiments by adding, changing, deleting, adding, etc. components within the same idea range, and this also falls within the idea range of the present invention.

Claims

1. A power relay assembly, comprising:

a support plate, which is provided with at least one electrical element on one surface and comprises a plastic material with heat dissipation and insulation properties;

at least one bus bar electrically connected to the electrical component; and

an electromagnetic wave shielding part for shielding electromagnetic waves generated by the electric element,

the bus bar is disposed to include a first portion completely buried or in contact with an inside of the support plate,

at least one part of the first part is connected with the part of the support plate, which is made of plastic material with heat dissipation and insulation,

the electromagnetic wave shielding part is a plate-shaped metal member having heat conduction, which is completely embedded in the support plate or fixed to the other surface of the support plate opposite to the surface to which the electric component is attached, and is disposed to be spaced apart from the first portion of the bus bar by a predetermined distance.

2. The power relay assembly of claim 1,

the metal member is disposed on the support plate so that a portion buried in the support plate or in contact with the support plate from the bus bar has an interval of 1mm or more.

3. The power relay assembly of claim 1,

on the surface of the metal member, a minute groove for improving the bonding force with the support plate is formed.

4. The power relay assembly of claim 1,

the metal member is electrically connected to ground via a cable.

5. The power relay assembly of claim 1,

the power relay assembly further includes at least one cover for preventing the bus bar from being exposed to the outside,

the electromagnetic wave shielding part is a shielding coating layer which has conductivity and is formed on the inner surface of the cover with a predetermined thickness.

6. The power relay assembly of claim 5,

the barrier coating layer is a coating layer coated with a polymer resin containing a conductive filler or a deposited layer deposited with a metal substance.

7. The power relay assembly of claim 1,

the support plate includes: a first plate made of a plastic material having insulation and heat dissipation properties; a second plate made of a plastic material having non-insulating and heat dissipating properties and containing a conductive filler, the second plate being laminated on one surface of the first plate;

the electromagnetic wave shielding part is the second plate.

8. The power relay assembly of claim 1,

at least a part of the bus bar is embedded in the support plate.

9. The power relay assembly of claim 8,

the support plate includes: a first plate for surface-contacting one surface of the first portion of the bus bar; and a second plate and a third plate, which are sequentially laminated on one surface of the first plate, and have arrangement holes formed therein, the arrangement holes having shapes corresponding to a part of the bus bars embedded in the support plate.

10. The power relay assembly of claim 9,

at least the first plate of the first plate, the second plate and the third plate is made of plastic with heat dissipation and insulation properties.

11. The power relay assembly of claim 8,

the support plate is formed by insert molding from a resin-forming composition having heat dissipation properties and insulation properties, and is integrated with a part of the bus bar embedded therein.